Generator with ferromagnetic teeth

ABSTRACT

A stator assembly for use in a superconducting generator operated at frequencies up to 10 Hz is disclosed. The stator assembly includes a ferromagnetic stator winding support having a plurality of teeth defining slots, the slots configured to receive and support stator windings. The stator winding support is formed so that the ratio of the sum of the widths of the slots to the sum of the widths of the teeth and slots is in the range of 0.65 to 0.90.

GOVERNMENT RIGHTS STATEMENT

The U.S. Government has a paid-up license in this invention and theright in limited circumstances to require the patent owner to licenseothers on reasonable terms as provided for by the terms of Contract No.70 NANB7H7055 awarded by the National Institute of Standards andTechnology/Advanced Technology Program.

BACKGROUND OF THE INVENTION

Power generation continues to be an important application of rotatingelectrical machines. Wind energy is one of the fastest growing sourcesof electricity in the United States and around the world, and windturbines employing rotating electrical machines are used to convert windenergy to usable power. The generator component of a wind turbineincludes the electrical generator, control electronics, and an optionalgearbox for converting the low speed incoming rotation to high speedrotation suitable for generating electricity. In a wind turbine, thegenerator component may be approximately one third of the overall windturbine cost.

In some conventional non-superconducting generators, stator windings aresurrounded by a back iron that acts as a magnetic flux path. The backiron is often in the form of stacked laminated plates, the platesincluding iron teeth that extend between the stator windings to providea flux path and to support the stator windings, which are positioned inslots formed between the teeth. In such machines, which often operate athigh frequencies of 60 Hz or greater, the teeth carry the magnetic flux,and the ratio of the area of slots to the area of teeth is about 50percent. This ratio is required in conventional machines to accommodatethe magnetic flux generated in these machines. In some conventionalmachines, tooth area is actually increased relative to slot area as ameans to reduce the cost of the machine, due to relative differences incost between iron and copper.

Superconducting generators have been under development since the early1960s. The use of superconducting windings in these machines hasresulted in a significant increase in the magnetomotive forces generatedby the windings and increased flux densities in the machines. The fluxdensities were increased to such an extent that there were high lossesdue to saturation of the iron teeth, as well as due to eddy currentlosses. As a result, superconducting machines have been developed tooperate without iron teeth between the stator coils since the fluxdensity would result in high dissipation in these members. In somecases, fiber-composite teeth, rather than iron teeth, are used tosupport stator coils in these machines. However, such fiber compositeteeth are very expensive to manufacture.

SUMMARY

In some aspects, a stator assembly for use in a rotating electricalmachine is provided. The stator assembly includes a stator coreincluding a plurality of teeth defining slots, the slots configured toreceive and support stator windings. The stator core is formed of aferromagnetic material, and the ratio of the sum of the widths of theslots to the sum of the widths of the teeth and slots is in the range of0.65 to 0.90.

The stator assembly may include one or more of the following features:The slots are elongate, radially extending openings formed in the statorcore. The teeth extend radially inward and are mutuallycircumferentially spaced apart. The stator assembly further includes atleast one stator winding disposed in a slot, and the stator windingincludes a coil formed of plural bundles of conductive wires. The statorcore includes an assembly of laminated plates. The ratio of the sum ofthe widths of the slots to the sum of the widths of the teeth and slotsis in the range of 0.70 to 0.90. The ratio of the sum of the widths ofthe slots to the sum of the widths of the teeth and slots is in therange of 0.75 to 0.90. The stator assembly further includes a statorwinding including a straight portion, wherein the straight portion isdisposed in one of the slots and the straight portion is configured tosubstantially fully occupy the slot. The cross sectional area of thestraight portion is substantially the same as the area of the slot. Thestator assembly further includes a stator winding including a straightportion, wherein there are multiple stator winding straight portionsdisposed in each slot. The cross sectional area of the straight portionis substantially half the area of the slot, and two stator windingstraight portions are disposed in each slot. The stator assembly furtherincludes at least one stator winding, the stator winding including acranked coil winding. The stator assembly further includes at least onestator winding including individual wire conductors arranged within theslot so that a radial conductor dimension is at least a factor of 1.5larger than the circumferential conductor dimension. The stator assemblyfurther includes at least one stator winding including individual wireconductors arranged within the slot so that a radial conductor dimensionis at least a factor of 2 larger than the circumferential conductordimension. The stator assembly further includes at least one statorwinding including individual wire conductors arranged within the slot sothat a radial conductor dimension is at least a factor of 3 larger thanthe circumferential conductor dimension.

In other aspects, a rotating electrical machine is provided. Therotating electrical machine includes a rotor assembly and a statorassembly. The stator assembly includes a stator core having a pluralityof teeth defining slots, the slots configured to receive and supportstator windings. The stator winding support is formed of a ferromagneticmaterial, and the ratio of the sum of the widths of the slots to the sumof the widths of the teeth and slots is in the range of 0.65 to 0.90.

The rotating electrical machine may include one or more of the followingfeatures: The rotor assembly includes a rotor having high temperaturesuperconducting windings. The rotor and stator assemblies are configuredto operate at frequencies up to 10 Hz. The rotor and stator assembliesare configured to operate at frequencies up to 3 Hz. The rotor andstator assemblies are configured to operate at a frequency of about 2Hz. The stator core is configured to have a tooth flux density duringoperation that is greater than 1.8 T. The stator core is configured tohave a tooth flux density during operation that is greater than 2.0 T.The stator core is configured to have a tooth flux density duringoperation that is greater than 2.2 T. The stator core is configured tohave a tooth flux density during operation that is greater than 2.4 T.The stator core is configured to have a tooth flux density duringoperation that is greater than 2.6 T. The stator core is configured tohave a tooth flux density during operation that is greater than 2.8 T.The machine further includes a stator winding having a straight portion,wherein the straight portion is disposed in one of the slots and thestraight portion is configured to substantially fully occupy the slot.The machine further includes a stator winding having a straight portion,wherein there are multiple stator winding straight portions disposed ineach slot. The machine further includes at least one stator windinghaving individual wire conductors arranged within the slot so that aradial conductor dimension is at least a factor of 1.5 larger than thecircumferential conductor dimension. The machine further includes atleast one stator winding, the stator winding including a cranked coilwinding. The machine further includes an air gap between the statorassembly and the rotor assembly that is greater than 15 mm. The machinefurther includes an air gap between the stator assembly and the rotorassembly that is greater than 20 mm.

Superconducting electric machines are ideally suited for use in windturbine applications as a wind-driven direct-drive generator. Due to thelow frequency (10 Hz or less) output of a wind turbine, a low costsuperconducting generator can be provided that includes stator windingsupport formed of a ferromagnetic material, without incurring the largepower losses associated with high operating frequency generators. Use ofa stator winding support formed of a ferromagnetic material results in arelatively low cost generator.

As will be described in greater detail below, the inventive statorassembly has features which contribute toward increasing the overallperformance, as well as reducing the overall manufacturing cost of a HTSgenerator. In particular, the low frequency superconducting generatorpermits a stator support design in which the ratio of overall slot areato overall support area is greater than 60 percent. Due to the relativelarge slot size, the cross sectional area of the conductor within theslot is much greater than in a conventional machine, providing increasedpower generation.

In some embodiments, by selecting a particular stator windingconfiguration, a single winding is disposed in a corresponding slot. Asa result, the cross sectional area of the conductor within the slot isfurther increased relative to other stator winding configurations, inwhich a single slot is occupied by leg portions of two or more statorwindings, and in which insulation disposed between individual legportions reduces overall conductor cross sectional area.

A generator includes a stator core formed of ferromagnetic laminationsand including plurality of teeth provided to support stator coilwindings. Use of ferromagnetic material to form the stator supportreduces manufacturing costs relative to use of fiber compositematerials. Although the ferromagnetic teeth of the stator support becomehighly saturated, the generator is operated at relatively low frequency,whereby the power losses associated with higher frequency machines dueto teeth saturation, as well as due to copper and heat generation, areminimized.

The superconducting synchronous generator can be shown to produce statortooth flux densities that are greater than 2.8 Tesla at generatoroperating frequencies of 10 Hz or less. In addition, employing an airgap greater than 15 to 20 mm between the stator and rotor assemblies inthese machines further reduces losses.

Modes for carrying out the present invention are explained below byreference to an embodiment of the present invention shown in theattached drawings. The above-mentioned object, other objects,characteristics and advantages of the present invention will becomeapparent from the detailed description of the embodiment of theinvention presented below in conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side sectional view of a generator.

FIG. 2 is an end perspective view of the stator and rotor assemblies ofthe generator of FIG. 1.

FIG. 3 is an partial sectional view of the stator core of the generatorof FIG. 1 without stator windings.

FIG. 4 is perspective view of a cranked stator winding where each sideoccupies a complete slot.

FIG. 5 is a partial sectional view of the stator core of the generatorof FIG. 1 with cranked stator windings disposed in the slots.

FIG. 6 is perspective view of the end turns of the cranked statorwindings within the stator core.

FIG. 7 is an open circuit magnetic flux profile for the generator ofFIG. 1.

FIG. 8 is a graph of arc length (meters) versus flux density (Tesla),representing air gap flux density in a generator havingnon-ferromagnetic teeth and a slot area to support area ratio greaterthan 0.60.

FIG. 9 is a graph of arc length (meters) versus flux density (Tesla),representing air gap flux density in a generator having ferromagneticteeth and a slot area to support area ratio greater than 0.60.

FIG. 10 is a graph of arc length (meters) versus flux density (Tesla),representing air gap flux density in a generator having ferromagneticteeth, a slot area to support area ratio greater than 0.60, and an airgap of greater than 15 mm.

FIG. 11 is a perspective view of a diamond stator winding.

FIG. 12 is a partial sectional view of the stator core of the generatorof FIG. 1 with diamond stator windings disposed in the slots.

FIG. 13 is a perspective view of a flat stator winding portion of asingle layer stator winding.

FIG. 14 is a perspective view of a upset-end winding portion of a singlelayer stator winding.

FIG. 15 is a perspective view of an assembly of multiple single layerstator windings.

DETAILED DESCRIPTION

Referring now to FIG. 1, generator 10 is a rotating superconductingmachine that includes a rotor assembly 40 mounted within a statorassembly 100. As will be described in greater detail below, thegenerator 10 is configured for use in low frequency applications of 10Hz or less. For example, when generator 10 is used as a generator in awind turbine, the rotor and stator assemblies 40, 100 are configured tooperate at about 2 Hz.

The rotor assembly 40 includes rotor windings 42 formed of ahigh-temperature superconductor (HTS), a torque transfer system 50, andan electromagnetic shield 60. The rotor windings 42 are supported by arotor winding support structure 44 within a cryostat 34. Although otherconfigurations are possible, the rotor windings 42 of this embodimentinclude several HTS sub-coils formed in a racetrack configuration. U.S.Pat. No. 6,509,819, the entire contents of which are incorporated hereinby reference, discusses exemplary rotor coil configurations in moredetail. The torque transfer system 50 transfers the rotational forcesgenerated by the rotor assembly to an output shaft 30, and is alsodisposed in the cryostat 34. The system 50 includes a torque tube 52connected at one end to the rotor winding support structure 44, and atthe other end to the output shaft 30 via an end plate 54. Theelectromagnetic shield 60 surrounds the cryostat 34 and consists of aconductive, non-magnetic material that shields rotor windings byattenuating asynchronous fields produced by the stator currents. Inaddition, the electromagnetic shield 60 shields the cryostat from heatgenerated in the stator assembly.

The generator 10 also includes a brushless exciter 16 to provide thecurrent to the rotor windings 42. The exciter 16 consists of atransformer and associated electronics (not shown) to condition andcontrol the power for the rotor windings 42. The rotor windings 42 areconduction cooled through the rotor support structure 44 using gaseoushelium, which circulates inside the cryostat 34 to cool the HTS rotorwindings 42. The coolant supply lines 48 that permit inward and outwardflow of the gaseous helium to the rotor assembly 40 pass through thecoaxial helium transfer coupling 14, which is a stationary-to-rotatingunion. Bearings 32 are mounted in a frame 24 to support opposed ends ofthe output shaft 30, whereby the rotor assembly 40 is rotatably andcoaxially supported within the stator assembly 100.

Referring to FIG. 2, the stator assembly 100 includes a stator core 102and stator windings 130. The stator core 102 is a hollow cylindricalbody 104 that is an assembly of stacked laminated ferromagnetic plates106. To form the stator core 102, the ferromagnetic plates 106 arepunched to provide the desired toothed shape, and the plates 106 arestacked to form the hollow cylindrical body 104 and fixed byconventional means such as epoxy.

Referring also to FIG. 3, the stator core 102 includes a back iron area108 adjacent to and including the outer diameter of the stator core 102,and multiple stator teeth 112 extend radially inward from the back ironarea 108 to form slots 114. Each tooth 112 has a tooth width w_(T), andall teeth 112 have approximately the same tooth width w_(T). The numberof teeth 112 provided depends in part on the configuration of the statorwinding 130 to be supported in the stator core 102. In the illustratedembodiment of generator 10, the stator core 102 is provided with 216stator teeth 112.

As viewed in cross section, the stator teeth 112 are regularly andmutually circumferentially spaced apart, the spacing between adjacentteeth 112 defining a stator slot 114. The stator slots 114 arerectangular in shape and have a slot width w_(S) corresponding to the(circumferential) distance between adjacent teeth 112. In thisembodiment, the rectangular shape of the stator slot 114 reflects therectangular peripheral shape of the straight portion of the statorwinding 130 to be received in the slot 114. The radially innermost edges112 a of the teeth 112 jointly define the cylindrical rotorassembly-receiving bore 116 of the stator core 102. Slot openings 120are defined between each pair of adjacent teeth 112, through whichstator windings 130 are inserted into the slot.

The rotor assembly 40 is supported within the bore 116 so that the rotorand stator assemblies 40, 100 are coaxial. With this arrangement, an airgap 118 is provided between an inner surface of the stator core 102(e.g., bore surface 116) and an outer surface 62 of the electromagneticshield 60.

In the illustrated embodiment of generator 10, the stator assemblyincludes 108 stator windings 130 arranged in a three or nine phaseconfiguration. For a three phase configuration, 36 stator windings 130per phase are provided, resulting in a 24-pole arrangement.

Referring to FIGS. 4-6, the stator windings 130 are formed of transposedwire cables 132, in which the individual copper wire conductors (157)are twisted and/or woven to form a pattern which reduces eddy currentlosses. The transposed cables 132 may include Litz wire, Rutherfordwire, Robel wire, or any other suitable transposed wire. The effect oftransposition can also be achieved by the use of end transpositionsbetween wires or selecting designs that use single wires in series foreach coil and operated in parallel at the end coil connections.

If the conductors 157 are rectangular in cross section, the conductorradially-directed dimension (ie, the dimension aligned with the slotdepth d_(S)) is longer than its circumferential dimension (ie, thedimension aligned with the slot width w_(S)) in order to lower the eddycurrent losses. A typical conductor 157 has a radial dimension tocircumferential dimension aspect ratio in a range of 1.5:1 to 5:1. Itshould be noted that the aspect ratio described here is opposite of whatis typical in conventional machines where the eddy current losses aredominated by cross-slot leakage in which magnetic flux lines jumpbetween two adjacent teeth. Multistrand Litz wires typically have a 1:1aspect ratio.

The transposed cables 132 have an outer insulative sheath, wherebyinsulation layer 152 is provided between turns, and the outer peripheryof the stator winding 130 includes a layer of ground insulation 150.

The transposed cables 132 are wound around an axis transverse to thelongitudinal axis of the stator assembly 100 to form an elongatedmulti-turn winding 130 including a parallel pair of straight portions136 connected by end turn portions 138. In this case, the stator winding130 is a cranked winding (FIG. 4) in which the straight portions 136 arelinear elongated members that extend in parallel. The end turn portions138 include a U-shaped turn 140 that lies in a plane transverse to theplane in which the straight portions 136 lie. As a result, one endwinding leg portion 138 a is located radially outward of the plane, andthe return leg end winding portion 138 b is located in the plane. Theparticular shape of the end portion 138 permits the stator windings 130to extend between respective slots 114 and to accommodate the presenceof the respective end portions 138 of the other stator windings 130(FIG. 6).

The straight portion 136 of the stator winding 130 is inserted into theslot 114 through the slot opening 120, and a slot wedge 156 is used toretain the stator winding 130 within the slot 114. In some embodiments,an insulative slot liner 154 is positioned in the slot 114 between thestator winding 130 and one side wall 114 a of the slot 114. In thisconfiguration, the slot liner 154 serves as packing within the slot toensure even loading. Alternatively, a slot liner 154′ (not shown) may beconfigured to surround the stator winding 130 on three sides, insulatingthe winding 130 from all slot walls. Use of a cranked winding 130 isadvantageous since the rectangular cross section of the straightportions 136 are well suited for use in the relatively wide slots 114provided in the stator core 102. In particular, the cross-sectional areaof the straight portion 136 is substantially the same as the slot areaA_(S) , where slot area A_(S) is defined as slot width w_(S) multipliedby slot depth d_(S) (FIG. 3), and the cranked stator winding 130substantially fully occupies the slot 114 (FIG. 5).

Referring again to FIG. 1, the stator windings 130 are electricallyconnected to an external power converter 25 via power supply lines 22,and when torque is applied to the rotor causing rotation of the outputshaft 30, alternating magnetic flux is produced which extends throughthe air gap 118 from the HTS rotor windings 42 and interacts with thestator 130 to generate power.

The stator windings 130 are cooled by conventional means. For example,in some embodiments, the stator windings 130 may be conduction cooled.In this example, the straight portions 136 can be conduction cooledthrough the back-iron 108, and the heat can be extracted by air flow ora liquid cooling jacket (not shown) on the outer diameter of the statorcore 102. The end turns 138 can be cooled by forced convection. In otherembodiments, the stator windings 130 may be air cooled. For example,lamination spacing (not shown) can be fabricated into the stator core102, and air can be ventilated from the inner diameter to the outerdiameter of the stator core 102 with forced convection. The end turns138 can also be cooled by forced convection. In other embodiments, thestator windings 130 can be cooled by direct liquid cooling. For example,the stator windings 130 can be cooled by direct contact with adielectric fluid with the addition of narrow cooling passages (notshown) within the stator slot area. In still other embodiments, thestator windings 130 can be fabricated with internal tubes built intowindings, and deionized water can be circulated in the tubes to providedirect cooling. In still other embodiments, the stator windings 130 canbe fabricated with external water cooling tubes, specifically, havingtubes built outside the ground insulation of the windings. Deionized orfresh water can be circulated in the tubes to provide stator windingcooling. In this case, copper fins can be potted with the tubes toimprove cooling on the outside surface of the ground plan insulation.

Referring again to FIG. 3, the stator core 102 is formed so that theoverall tooth width w_(T) is small relative to the overall slot widthw_(S). In particular, the ratio of the sum of the widths of the slots tothe sum of the widths of the teeth and slots is in the range of 0.65 to0.90, where the sum of the widths of the slots is defined as

Sum_(wS) =Σw _(S1) +w _(S2) +w _(S3) + . . . +w _(SN),

the sum of the widths of the teeth and slots is defined as

Sum_(wS+wT)=w_(S1)+w_(S2)+w_(S3)+ . . . +w_(SN)+w_(T1)+w_(T2)+w_(T3)+ .. . +w_(TN), and N is the number of slots in the stator core 102. In theillustrated embodiment, N=216, but the stator core 102 is not limited tothis number of slots.

In other embodiments, the ratio of the sum of the widths of the slots tothe sum of the widths of the teeth and slots is in the range of 0.70 to0.90. In still other embodiments, the ratio of the sum of the widths ofthe slots to the sum of the widths of the teeth and slots is in therange of 0.75 to 0.90.

In some embodiments of the generator 10, the slot width w_(S) may be atleast twice as large as the tooth width w_(T), and the main function ofthe teeth in this device is to provide support for the stator windings130. A stator core formed having a ratio of the sum of the widths of theslots to the sum of the widths of the teeth and slots as disclosed hereis novel since in high frequency machines such slot to tooth proportionsare associated with high losses and associated limits in power output.In contrast, in the generator 10, the relatively large slot area permitsuse of additional conductor within the slot, which is advantageous sincepower losses decrease with increased conductor area particularly whenthe conductor is subdivided and effectively transposed. Alsoadvantageously, although the stator teeth 114 of generator 10 mainlyserve to support the stator windings 130, use of the ferromagneticmaterial therein also results in a modest increase (about 10 percent) inair gap flux.

In addition, because the generator 10 is operated at low frequencies (upto 10 Hz), the eddy current losses associated with ferromagnetic teethand the copper conductors in the slots are reduced.

Further advantageously, use of a ferromagnetic material to form thestator teeth 114 permits the generator 10 to be inexpensivelymanufactured.

When generator 10 is operated at a low frequency, for example at about 2Hz, the tooth flux density is greater than 1.8 Tesla. As seen in FIG. 7,which illustrates calculated flux density over a portion the stator androtor assemblies the tooth flux density is shown to be greater than 3.0Tesla. Thus, the generator 10 is configured to operate with fluxsaturated teeth, and during operation, teeth 114 of generator 10 are ata much higher flux density than in conventional superconductinggenerators, which generally operate with teeth having a flux density ofless than 1.8 Tesla. However, due to the low frequency operation ofgenerator 10, although the teeth 114 are saturated, the resulting losses(as scaled from ARMCO tables) are less than 10 kW.

Referring now to FIG. 8, the flux density in the air gap, as measured atthe surface 62 of the electromagnetic shield 60, is shown for asuperconducting generator that includes a stator core formed withnon-ferromagnetic teeth (ie, composite or stainless steel) but includinga stator core in which ratio of the sum of the widths of the slots tothe sum of the widths of the teeth and slots is in the range of 0.65 to0.90. This graph shows a flux density that is greater than 1 Tesla inthe air gap. This flux density is greater than in some conventionalmachines, which have an air gap flux density of about 1 Tesla. Thisgraph illustrates that more power is produced in the air gap relative toa conventional machine due to the use of HTS rotor coils, and furtherillustrates that the inventive stator construction, including a ratio ofthe sum of the widths of the slots to the sum of the widths of the teethand slots in the range of 0.65 to 0.90, does not prevent adequate powerproduction.

There are limitations to the use of ferromagnetic saturated teeth. Forexample, the electromagnetic shield 60 can have additional losses duethe field changes associated with tooth passing. Referring now to FIG.9, the flux density in the air gap, as measured at the surface 62 of theelectromagnetic shield 60, is shown for a superconducting generator thatincludes a stator core formed with ferromagnetic teeth and including astator core in which the ratio of the sum of the widths of the slots tothe sum of the widths of the teeth and slots is in the range of 0.65 to0.90. This graph shows a flux density that includes some harmoniccontent as represented by localized peaks at about 0.09 m and 0.18 m.Such harmonic content is undesirable since it results in heating on theelectromagnetic shield 60, and thus power loss in the rotor assembly 40.However, as seen in FIG. 10, such harmonic content can be avoided byincreasing the air gap 118. For example, in some embodiments, generator10 can include an air gap of greater than 15 mm. In other embodiments,generator 10 can include an air gap of greater than 20 mm. For purposesof comparison, in a conventional generator of comparable size, an airgap of 5 to 10 mm is often used. Thus, a relatively large air gap 118 isbeneficial for use in a low speed system as embodied by generator 10.

The generator 10 has been described here as employing cranked statorwindings 130. However, the generator 10 is not limited to use of thecranked stator winding 130, and it is well within the scope of theinvention to use windings of other configurations, such as, but notlimited to, diamond windings 230 or single layer windings 330.

Referring now to FIG. 11, a diamond winding 230 includes transposedcables 132 wound in a generally diamond shape. The diamond windings 230are arranged within the stator slots 114 by overlapping straightportions 236 of adjoining windings in the same phase, whereby each slot114 receives two windings 230. In particular, one straight portion 236 aoccupies the radially inward location of one slot 114, and the otherstraight portion 236 b occupies the radially outward location of anotherslot 114. Standard diamond windings have an end geometry that makes itdifficult to achieve a greater slot fill than about 50 percent. As seenin FIG. 12, the cross-sectional area of the straight portion 236 isabout half of the slot area A_(S), and the straight portion 236 of thediamond winding 230 occupies about half of the slot 114. Due to thepresence of ground insulation 150 on each diamond winding, a doublelayer of insulation is formed between the two windings 230 disposed inthe slot 114, having the effect that the amount of conductor in the slot114 when using a diamond winding 230 is less than when using a crankedwinding 130.

Referring now to FIGS. 13-15, a single layer winding 330 includes a flatstator winding 330 a (FIG. 13) used in combination with a upset-endstator winding 330 b (FIG. 14). In the flat stator winding 330 a, theend turn portion 338 a is U-shaped and lies in the same plane as thestraight portion 336 a. In the upset-end stator winding 330 b, the endturn portion 338 b is U-shaped but extends upward from the plane definedby the straight portions 336 b. When assembled together (FIG. 15), thestraight portion 336 b of the upset-end stator winding 330 b residesbetween, and in the same plane as, the straight portions 336 a of theflat stator winding 330 a. In addition, the end turn portion 338 b ofthe upset-end stator winding lies parallel to, and partially overlies,the end turn portion 338 a of the flat stator winding 330 a. Like thecranked winding 130, the cross-sectional area of the straight portion336 a, 336 b is substantially the same as the slot area A_(S), and thesingle layer winding 330 substantially fully occupies the slot 114. Inaddition, the single layer winding has a better conductor packing factorthan the cranked winding 130 due to differing insulation requirements.However, the single layer coil 330 may be more difficult to install andsupport than the single layer winding 130.

A selected illustrative embodiment of the stator assembly 100 for use inthe generator 10 is described above in some detail. However, the statorassembly as described herein is not limited to use in a generator. Forexample, the stator assembly can be used in other types of rotatingelectrical machines, including high torque, low speed motors.

In addition, it should be understood that only structures considerednecessary for clarifying the present invention have been describedherein. Other conventional structures, and those of ancillary andauxiliary components of the system, are assumed to be known andunderstood by those skilled in the art. Moreover, while a workingexample of the present invention has been described above, the presentinvention is not limited to the working example described above, butvarious design alterations may be carried out without departing from thepresent invention as set forth in the claims.

1. A stator assembly for use in a rotating electrical machine, thestator assembly comprising: a stator core including a plurality of teethdefining slots therebetween, the slots configured to receive and supportstator windings, the stator core being formed of a ferromagneticmaterial, and wherein the ratio of the sum of the widths of the slots tothe sum of the widths of the teeth and slots is in the range of 0.65 to0.90.
 2. The stator assembly of claim 1, wherein the slots are elongate,radially extending openings formed in the stator core.
 3. The statorassembly of claim 1, wherein the teeth extend radially inward and aremutually circumferentially spaced apart.
 4. The stator assembly of claim1, further comprising at least one stator winding disposed in a slot;the stator winding including a coil formed of plural bundles ofconductive wires.
 5. The stator assembly of claim 1, wherein the statorcore includes an assembly of laminated plates.
 6. The stator assembly ofclaim 1, wherein the ratio of the sum of the widths of the slots to thesum of the widths of the teeth and slots is in the range of 0.70 to0.90.
 7. The stator assembly of claim 1, wherein the ratio of the sum ofthe widths of the slots to the sum of the widths of the teeth and slotsis in the range of 0.75 to 0.90.
 8. The stator assembly of claim 1,further comprising a stator winding including a straight portion,wherein the straight portion is disposed in one of the slots and thestraight portion is configured to substantially fully occupy the slot.9. The stator assembly of claim 8, wherein the cross sectional area ofthe straight portion is substantially the same as the area of the slot10. The stator assembly of claim 1, further comprising a stator windingincluding multiple stator winding straight portions disposed in eachslot.
 11. The stator assembly of claim 10 wherein the cross sectionalarea of a straight portion is substantially half the area of the slot,and two stator winding straight portions are disposed in each slot. 12.The stator assembly of claim 1, further comprising at least one statorwinding, the stator winding comprising a cranked coil winding.
 13. Thestator assembly of claim 1, further comprising at least one statorwinding including individual wire conductors arranged within the slot sothat a radial conductor dimension is at least a factor of 1.5 largerthan the circumferential conductor dimension.
 14. (canceled)
 15. Thestator assembly of claim 1, further comprising at least one statorwinding including individual wire conductors arranged within the slot sothat a radial conductor dimension is at least a factor of 3 larger thanthe circumferential conductor dimension.
 16. A rotating electricalmachine comprising: a rotor assembly; and a stator assembly, the statorassembly including a stator core including a plurality of teeth definingslots, the slots configured to receive and support stator windings, thestator winding support being formed of a ferromagnetic material, andwherein the ratio of the sum of the widths of the slots to the sum ofthe widths of the teeth and slots is in the range of 0.65 to 0.90. 17.The machine of claim 16, wherein the rotor assembly includes a rotorhaving high temperature superconducting windings.
 18. The machine ofclaim 16, wherein the rotor and stator assemblies are configured tooperate at frequencies up to 10 Hz.
 19. (canceled)
 20. (canceled) 21.The machine of claim 16, wherein the stator core is configured to have atooth flux density during operation that is greater than 1.8 T. 22.(canceled)
 23. (canceled)
 24. (canceled)
 25. (canceled)
 26. The machineof claim 16, wherein the stator core is configured to have a tooth fluxdensity during operation that is greater than 2.8 T. 27.-30. (canceled)31. (canceled)
 32. (canceled)
 33. A wind turbine comprising: a rotatingelectrical machine, said rotating electrical machine having a rotorassembly; and a stator assembly, the stator assembly including a statorcore including a plurality of teeth defining slots, the slots configuredto receive and support stator windings, the stator winding support beingformed of a ferromagnetic material, and wherein the ratio of the sum ofthe widths of the slots to the sum of the widths of the teeth and slotsis in the range of 0.65 to 0.90.